External fixation

ABSTRACT

An orthopedic external fixation system may include a distal bar having a curvature that varies along its length, an uncurved proximal bar, a plurality of proximal embedding members, and a plurality of distal embedding members. The proximal and the distal embedding members, sized and shaped for embedding in bone, may attach directly or indirectly to the proximal bar and the distal bar, respectively.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. Application Ser. No. 11/683,418, filed on Mar. 7, 2007, now U.S. Pat. No. 8,277,448, issued on Oct. 2, 2012, the entirety of which is incorporated by reference herein.

SUMMARY

An orthopedic external fixation system may include a distal bar having a curvature that varies along its length, an uncurved proximal bar, a plurality of proximal embedding members, and a plurality of distal embedding members. The proximal and the distal embedding members, sized and shaped for embedding in bone, may attach directly or indirectly to the proximal bar and the distal bar, respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of an embodiment of an external fixation system.

FIG. 2 shows an embodiment of a distal bar having an uncurved portion and a curved portion following the curvature of a noncircular ellipse.

FIG. 3 shows an embodiment of a distal bar having an uncurved portion and a semicircular curved portion, with a plurality of distal embedding members extending from the distal bar into bone.

FIG. 4 shows an exemplary use of an embodiment illustrated in FIG. 1 with a plurality of distal embedding members extending from the distal bar into bone.

FIGS. 5-6 show perspective view and a side view, respectively, of a proximal embedding member connector.

FIGS. 7-9 illustrate perspective, a front view of an unlocked configuration, and a front view of a locked configuration, respectively, of a distal embedding member connector.

FIG. 10 illustrates connector motions along a distal bar.

FIG. 11 illustrates various degrees of freedom in an embodiment of an external fixation system.

FIG. 12 shows an embodiment with a distal bar having multiple linear segments.

DETAILED DESCRIPTION

An external fixation system is used to stabilize fractured bone fragments in a relative alignment that facilitates bone healing. An external fixation system typically includes a number of pins, wires, and/or screws percutaneously inserted into bone fragments and clamped to one or more anchoring bars or rods. In the case of nonbridging external fixation of a distal radius fracture, a proximal bar may be fixed to the radius proximal to the fracture by threaded pins or screws, and a distal bar may be fixed to one or more fragments of the radius, distal to the fracture, by K-wires. The distal bar, or a portion thereof, may be curved, as described in more detail below. Fracture stability is achieved by insertion of K-wires, along one or more planes, into the distal bone fragment(s) and attaching the K-wires to the distal bar. The distal bar is then connected to the proximal bar.

FIG. 1 shows a perspective view of an external fixation system 10 having a distal bar 14, an uncurved proximal bar 12, and a plurality of proximal embedding members 16 (“proximal pins”) and proximal embedding member connectors 24. A plurality of the proximal pins 16 may be fixed to the arm of a patient and connected to the proximal bar 12 to serve as an anchor for the external fixation system 10. The proximal embedding member connectors 24 may be positioned along the length of the uncurved proximal bar 12 to anchor the proximal pins 16 appropriately. The proximal bar may optionally have detents or other surface features that mate with a proximal embedding member to define preferred connection positions. The proximal embedding member connectors 24 can be clamped at various positions along the length of the proximal pin 16.

A plurality of proximal embedding members 16 may be attachable to the proximal bar 12 directly or indirectly. Direct attachment between the proximal embedding member and the proximal bar may involve the two components making contact with one another. For example, a proximal bar may have holes sized and shaped to receive a proximal embedding member by press-fit. Holes in the proximal bar may be threaded to receive complementary threads on proximal embedding members. Direct attachment may also be accomplished by the proximal bar having a built-in clamp or other mechanisms to connect the proximal embedding member to the proximal bar without the need for an intermediate component. A proximal embedding member may also be glued to a proximal bar for direct attachment.

Indirect attachment between the proximal embedding member 16 and the proximal bar 12 may include an intermediate clamp to which both components are connected. For example, FIG. 1 shows a plurality of a proximal embedding member connectors 24 connecting a proximal embedding members to a proximal bar.

Distal embedding members 23 may be attachable to a distal bar 14 directly or indirectly in the various ways described above for proximal embedding members and a proximal bar.

The proximal bar may be fixed relative to the patient's forearm by attaching it to the radius with at least two pins/screws, typically positioned at least several centimeters apart from one another along the length of the proximal bar. When so attached, the proximal bar is typically oriented so that it runs parallel to the shaft of the radius, with respect to both the pitch of the bar and its medial/lateral skew with respect to the shaft of the radius, but nonparallel orientations, in pitch and/or skew, are also possible.

A proximal embedding member connector 24 may also connect the distal bar 14 to the uncurved proximal bar 12. FIG. 1 is an illustration of one possible attachment point between the distal bar 14 and the proximal uncurved bar 12. The distal bar 14 may be attached at different points along the length of the proximal uncurved bar 12.

The distal bar 14 has an uncurved portion 26 and a curved portion 27 and lies in a plane transverse (such as perpendicular or oblique) to the proximal bar. The curved portion may curve in a plane transverse to the proximal bar. A plurality of distal embedding member connectors 22 may connect and fix distal embedding members (such as K-wires, not shown) to the distal bar. Proximal and distal embedding members may include radioopaque features to facilitate radiographic confirmation of proper placement.

The proximal and distal bars may have a variety of shapes and sizes. It may have a circular cross-section, round cross-section, elliptical cross-section, polygonal cross-section, and/or square cross-section. If the cross-section has flat sides, the edges defining the sides may be rounded. A bar may have a diameter in the range of about 1 mm to about 12 mm, about 3 mm to about 11 mm, about 3 mm, about 4 mm, about 5 mm, about 8 mm, and/or about 11 mm. The diameter of a bar may be constant along the length of the bar or may vary. (If the bar has other than a circular cross-section, the “diameter” refers to the longest segment that can be obtained by joining two points at the edge of the cross-section.) A bar may be solid or hollow inside. A bar may have a length in the range of about 3 cm to about 30 cm.

The proximal and distal bars may be made of a wide variety of materials. The bars may be made, in whole or in part, from carbon fiber, metal, stainless steel, titanium, aluminum (such as grades 6061 and 7075), plastic, polysulfone, polyether sulfone (such as RADEL®-A plastic resin), polyphenylsulfone (such as RADEL®-R plastic resin), among others. A bar may be radiolucent. A bar may be of unitary construction (i.e., is formed from a single piece of material, without any joints or connections) or may be formed by joining two or more pieces together.

The length of the uncurved portion 26 of the distal bar may be in the range of about 4 centimeters to about 6 centimeters. The curved portion 27 of the distal bar may curve through an arc of at least 45 degrees, at least 60 degrees, at least 90 degrees, between about 90 degrees and about 180 degrees, about 180 degrees, and/or at least 180 degrees. The curved portion 27 of the distal bar 14 may have a constant curvature or a nonconstant curvature. A nonconstant curvature may follow a sector of, for example, a noncircular ellipse, a hyperellipse, a hypoellipse, an oval, a parabola, a hyperbola, or an involute, among other shapes. The distal bar 14 may have a first portion having a first curvature and a second portion having a second curvature which is different from the first curvature.

One or more curved portions of the distal bar 14 may follow a sector of a circle. The distal bar 14 may curve through at least ⅛ of the circumference of a circle, at least ⅙ of the circumference of a circle, at least ¼ of the circumference of a circle, between ¼ and ½ of the circumference of a circle, about ½ of the circumference of a circle, and/or at least ½ of the circumference of a circle. The circle that the distal bar curved portion follows may have a radius in the range of about 0.5 inches to about 5 inches, about 1 inch to about 2 inches, about 1 inch, exactly 1 inch, about 1.5 inches, exactly 1.5 inches, about 2 inches, and/or exactly 2 inches.

One or more curved portions of the distal bar 14 may follow the curvature of a noncircular ellipse. The distal bar 14 may follow the curvature of an ellipse having a major axis of about 7 cm in length and a minor axis of about 5 cm in length. The distal bar 14 may follow the curvature of an ellipse having a major axis of about 6 cm in length and a minor axis of about 4 cm in length. Alternatively, the distal bar 14 may follow the curvature of an ellipse having an eccentricity in the range of about 0.5 to about 0.8, about 0.6 to about 0.8, and/or about 0.69 to about 0.75. (Eccentricity of an ellipse is an unitless quantity that indicates deviation from a circular shape and is defined to equal √{square root over (1−(b²/a²))}, where a and b are the major and minor axes, respectively, of the ellipse. A circle has an eccentricity of zero and a noncircular ellipse has an eccentricity that is greater than zero but less than one. The eccentricity of an ellipse that reasonably approximates the cross-section of a human wrist typically falls in the range of about 0.6 to about 0.8. The eccentricity of an ellipse that reasonably approximates the cross-section of a human finger typically falls in the range of about 0.5 to about 0.6.) The distal bar 14 may curve through at least ⅛ of the circumference of an ellipse, at least ⅙ of the circumference of an ellipse, at least ¼ of the circumference of an ellipse, between ¼ and ½ of the circumference of an ellipse, about ½ of the circumference of an ellipse, and/or at least ½ of the circumference of an ellipse.

The distal bar 14 may be positioned on the skin or with space between it and the patient's skin to allow for postoperative swelling. The distal bar may be spaced apart from the skin at distance in the range of 0 cm to about 3 cm, 0 cm to about 2 cm, 0 cm to about 1.5 cm, about 1 cm to about 1.5 cm, and/or about 0.5 cm to 1.5 cm. For example, the distal bar may be designed to follow a curve appropriately larger than the relevant portion of the patient's anatomy. If no swelling is expected, then a bar that contacts or lies within a few millimeters of the skin may be used to provide a low-profile fixation system.

FIG. 2 shows an embodiment of a distal bar. In the depicted embodiment, the distal bar 14 has a curved portion 27 and an uncurved portion 26. The curved portion extends from one end of the uncurved portion and follows an elliptical curve through somewhat more than ¼ of the circumference of the ellipse. The ellipse that the curved portion follows has major and minor axes that exceed the major and minor axes, a and b, respectively, of the depicted ellipse that approximates the cross-section of the anatomy about which the bar is positioned (such as the forearm in the vicinity of the distal radius).

FIG. 3 depicts another embodiment of a distal bar. In this embodiment, the curved portion has a constant curvature (i.e., it is circular) and curves through an arc of 180 degrees (i.e., it has a semicircular shape). This distal bar may be termed a “J-bar” in view of its shape. FIG. 3 also depicts an exemplary use of the distal bar. Each of a plurality of distal embedding members 23 (such as K-wires) extend from the distal bar into a bone fragment F. The distal embedding members may be so oriented and positioned relative to one another that they form a “subchondral scaffold” of wires that support the fragment in one or more planes. The distal embedding members may also be oriented to cross the fracture lines.

In one exemplary use shown in FIG. 4, the system is used in the repair of a distal radius fracture. In such a scenario, the curved portion 27 of the distal bar 14 may be sized an shaped so that it wraps around the patient's distal forearm on the radial (anatomically lateral) side. The proximal bar is fixed to the shaft of the radius with pins and connectors. The distal bar is fixed to the proximal bar by a connector. A plurality of K-wires are fixed to the distal bar by connectors and embedded in the distal radius fragments. The curved portion of the distal bar permits placement of the K-wires at a wide variety of angles from several positions around the distal radius without the need to bend or otherwise distort the wires. Using unbent K-wires helps minimize wobble, shift, torque, and shear stress. The K-wires may, however, be bent and still provide enough support if proper placement into the distal fragment requires it.

FIGS. 5 and 6 illustrate an embodiment of a proximal embedding member connector 24 having two grooved blocks 32. The blocks may be identical to one another. The block defines a groove, such as C-shaped groove. In the depicted embodiment, the blocks define C-shaped grooves 34 that are oriented perpendicular to one another. The two blocks 32 may be oriented at other angles with respect to each other, so that the grooves 34 may be oriented in a wide range of angles depending on a patient's need. The grooves may be sized and shaped to receive the uncurved proximal bar 12 and/or the proximal pins 16. Once a desired position of the proximal embedding member connectors 24 is obtained, a locking screw 30 may simultaneously lock the two C-groove blocks 32 to each other and fix the locked blocks to the uncurved proximal bar 12 as shown in FIG. 1. By tightening the screw, the clamping force is applied and two blocks 32 will come together until they contact one another. FIG. 6 represents an embodiment of an unlocked configuration of a proximal embedding member connector 24.

FIGS. 7-9 show various views of an exemplary embodiment of a distal embedding member connector 22. The depicted embodiment includes a C-groove block 47 and J-block 48, each having a groove to receive a distal bar 14 and a distal embedding member 20, respectively. FIG. 8 illustrates the exemplary distal embedding member connector in an unlocked configuration. As for the proximal embedding member connector, a locking screw (not shown) may bring the J-block 48 and the C-groove block 47 until they contact one another to secure the distal embedding member 20 to the distal embedding member connector 22 and fix the position of the distal member connector 22 with respect to the distal bar 14. Distal embedding member connectors 22 may be positioned along the length of the uncurved portion of the distal bar 14 as shown in FIG. 1.

Distal embedding member connectors 22 may slide and/or rotate along and with respect to the distal bar (FIG. 10) These motions, taken with other possible adjustments (shown in FIG. 11), illustrate the various ways by which the distal bar position and orientation may be controlled.

The C-shaped groove 40 and the through hole 46 may be connected by a v-shaped cutout 44 as shown in FIG. 8. The v-shaped cutout 44 or other similar shapes that have a decreasing width may facilitate clamping of the distal embedding member connector 22 by providing initial resistance to connection that abruptly gives way with a click to provide audible and tactile confirmation of correct positioning.

Some or all portions of the proximal and/or distal embedding member connectors may be made with radiolucent material such as carbon fiber.

FIG. 12 shows a distal bar 50 for an external fixation system having a plurality of linear segments 52 bent at angles relative to one another. The distal bar 50 may have one, two, three, four, five, six, or more linear segments. Adjacent linear segments 52 may extend relative to one another at an angle α in the range of about 5 degrees to about 20 degrees, separately for each occurrence. The distal embedding member connectors 22 as shown in FIG. 1 may be used in this configuration to secure the distal embedding members 20 to the linear segments 52. In some embodiments, there may be a single linear segment 52 which may extend from the rest of the bar at a variety of angle. If that single linear segment extends at an angle of or about 90 degrees, then the bar may be termed an “L-bar.”

As discussed previously, external fixation systems described herein may be used to provide non-bridging fixation for fractures of the distal radius. They may also be used to provide spanning fixation and/or distraction across a distal radius fracture and/or across one or more bones of the carpus. The disclosed external fixation systems may also be used in treating fractures of other bones, such as metacarpals, phalanges in hands or feet, ulna, humerus, clavicle, scapula, the bony pelvis, femur, tibia, fibula, bones of the ankle, and/or metatarsals. segments are bent at angles in the range of about 5 degrees to about 20 degrees relative to one another. 

We claim:
 1. An external fixation system comprising: at least one distal embedding member connector including: a first block including opposed curved surfaces that together define a c-shaped groove sized and configured to engage a bar having a circular outer surface, the c-shaped groove located adjacent to a first side surface of the first block, a first hole is defined adjacent to a second side surface of the first block and extending parallel to the c-shaped groove, and a cutout extending between and connecting the c-shaped groove and the first hole, the c-shaped groove is accessible via the first side surface and the cutout has a decreasing width along its entire length such that the cutout is narrower adjacent to the first hole than it is adjacent to the c-shaped groove, a second block including a second hole sized and configured to receive a distal embedding member therein, and a locking screw configured to couple the first block to the second block.
 2. An orthopedic external fixation system according to claim 1 further comprising a distal bar comprising a plurality of linear segments bent at angles relative to one another.
 3. An orthopedic external fixation system according to claim 2 wherein the distal bar includes at least three linear segments.
 4. An orthopedic external fixation system according to claim 2 wherein adjacent segments are bent at angles in the range of about 5 degrees to about 20 degrees relative to one another.
 5. An orthopedic external fixation system according to claim 1 further comprising a distal bar comprising: an uncurved portion having zero curvature; and a curved portion having a curvature that approximates a curvature of a noncircular ellipse.
 6. An orthopedic external fixation system according to claim 5 wherein the uncurved portion of the distal bar has a length in the range of about 4 to about 6 centimeters.
 7. An orthopedic external fixation system according to claim 5 wherein the curved portion of the distal bar curves through an arc of no less than 45 degrees.
 8. An orthopedic external fixation system according to claim 7 wherein the curved portion of the distal bar curves through an arc of at least 60 degrees.
 9. An orthopedic external fixation system according to claim 7 wherein the curved portion of the distal bar curves through an arc of at least 90 degrees.
 10. An orthopedic external fixation system according to claim 7 wherein the curved portion of the distal bar curves through an arc of between about 90 degrees and about 180 degrees.
 11. An orthopedic external fixation system according to claim 7 wherein the curved portion of the distal bar curves through an arc of about 180 degrees.
 12. An orthopedic external fixation system according to claim 7 wherein the curved portion of the distal bar curves through an arc of at least 180 degrees.
 13. An orthopedic external fixation system according to claim 7 wherein the curvature of the curved portion is defined by a constant radius of curvature.
 14. An orthopedic external fixation system according to claim 7 wherein the curvature of the curved portion is defined by a variable radius of curvature.
 15. An orthopedic external fixation system according to claim 1 further comprising a distal bar including a first portion having a first curvature and a second portion having a second curvature different from the first curvature.
 16. An orthopedic external fixation system according to claim 1 further comprising a distal bar having a curvature defined by a noncircular ellipse.
 17. An orthopedic external fixation system according to claim 1 further comprising a distal bar having a curvature defined by an ellipse having a major axis of about 7 cm in length and a minor axis of about 5 cm in length.
 18. An orthopedic external fixation system according to claim 1 further comprising a distal bar having a curvature defined by an ellipse having an eccentricity in the range of about 0.6 to about 0.8.
 19. An orthopedic external fixation system according to claim 1 further comprising a distal bar having a curvature defined by an ellipse having an eccentricity in the range of about 0.69 to about 0.75.
 20. An orthopedic external fixation system according to claim 1 further comprising a distal bar that curves through at least ⅛ of a circumference of an ellipse.
 21. An orthopedic external fixation system according to claim 1 further comprising a distal bar that curves through at least ⅙ of a circumference of an ellipse.
 22. An orthopedic external fixation system according to claim 1 further comprising a distal bar that curves through at least ¼ of a circumference of the ellipse.
 23. An orthopedic external fixation system according to claim 1 further comprising a distal bar that curves through between about ¼ and ½ of a circumference of an ellipse.
 24. An orthopedic external fixation system according to claim 1 further comprising a distal bar that curves through about ½ of a circumference of an ellipse.
 25. An orthopedic external fixation system according to claim 1 further comprising a distal bar that curves through at least ½ of a circumference of an ellipse.
 26. An orthopedic external fixation system according to claim 1 further comprising a proximal bar that defines a plurality of through holes.
 27. An orthopedic external fixation system according to claim 1 further comprising a distal bar made at least in part of carbon fiber.
 28. An orthopedic external fixation system according to claim 1 wherein the distal embedding members comprise K-wires. 